Honda HRX217K6HYA Manual Download

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10-18

CAM PULLEY/CRANKSHAFT/ PISTON/CYLINDER

HRX217HYA • HRX217HZA

CONNECTING ROD SMALL END I.D.

Measure the connecting rod small end I.D.

If the measurement is more than the service limit, replace the

connecting rod.

CONNECTING ROD BIG END I.D.

Set the connecting rod cap to the connecting rod. Be sure the

projections align properly.

Apply engine oil to the connecting rod bolt threads and seating

surface.

Tighten the connecting rod bolts to the specified torque.

Measure the connecting rod big end I.D.

If the measurement is more than the service limit, replace the

connecting rod and connecting rod cap.

CRANKSHAFT MAIN JOURNAL O.D.

Measure the crankshaft main journal O.D.

PTO side:

Flywheel side:

If the measurement is less than the service limit, replace the

crankshaft.

STANDARD:

13.005 – 13.020 mm (0.5120 – 0.5126 in)

SERVICE LIMIT:

13.07 mm (0.515 in)

TORQUE:

12 N•m (9 ft-lb)

STANDARD:

28.020 – 28.033 mm (1.1031 – 1.1036 in)

SERVICE LIMIT:

28.066 mm (1.1050 in)

STANDARD:

27.980 – 27.993 mm (1.1016 – 1.1021 in)

SERVICE LIMIT:

27.933 mm (1.0997 in)

STANDARD:

25.380 – 25.393 mm (0.9992 – 0.9997 in)

SERVICE LIMIT:

25.333 mm (0.9974 in)

Summary of Contents for HRX217K6HYA

Page 1: ...sing safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or work around pressuriz...

Page 2: ...isions we have provided safety messages and other safety information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing these mowers You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the mower Safety Messages preceded by a safety alert symbol and o...

Page 3: ...ii NOTES ...

Page 4: ...1 1 1 SPECIFICATIONS 1 SPECIFICATIONS 1 2 3 WIRING DIAGRAM HZA TYPE 1 4 2 DIMENSIONAL DRAWINGS 1 3 ...

Page 5: ...d valve single cylinder Displacement 201 cc 12 3 cu in Bore x stroke 66 x 59 mm 2 6 x 2 32 in Compression ratio 8 0 1 Maximum governed speed 3 100 0 150 rpm Ignition system Transistorized magneto ignition Ignition timing 20 B T D C Fuel supply system Gravity feed with a manual shut off valve Lubrication system Splash type Cooling system Forced air Starting system Recoil starter Charge system HZA t...

Page 6: ...1 3 HRX217HYA HRX217HZA SPECIFICATIONS 2 DIMENSIONAL DRAWINGS 678 mm 26 7 in 588 mm 23 1 in 530 mm 20 9 in 1 122 mm 44 1 in 1 665 mm 65 5 in HZA type shown ...

Page 7: ...SE 30A SLO BLO 2P250 B R B R B R B R CHARGE COIL ENG EARTH B STARTER B B B R SPARK PLUG CHG IGN COIL COIL MINI BLADE HOLDER 3A FUSE 5P250 COMB SW 4P250 ST E BAT IG B M S L G B R R R B R B Y W B Y R R W B W R B W B Y R W BLACK YELLOW RED WHITE WIRE COLOR OFF ON START IG E BAT ST COMB SW MODE ...

Page 8: ...d operation 2 SYMBOLS USED IN THIS MANUAL As you read this manual you may find the following symbols with the instructions 1 SERVICE RULES 2 1 6 TOOLS 2 5 2 SYMBOLS USED IN THIS MANUAL 2 1 7 TROUBLESHOOTING 2 7 3 SERIAL NUMBER LOCATIONS 2 2 8 TROUBLESHOOTING TECHNIQUES 2 12 4 SERVICE SPECIFICATIONS 2 3 9 CABLE ROUTING AND TIES 2 26 5 TORQUE VALUES 2 4 A special tool is required to perform the proc...

Page 9: ...wer deck between the Clip Director knob and rear discharge chute The engine serial number is located on the crankcase below the fuel valve on the left hand side of the engine Refer to the frame serial number or engine serial number when ordering parts and when making technical inquiries ENGINE SERIAL NUMBER FRAME SERIAL NUMBER ...

Page 10: ...5124 13 048 0 5137 Piston pin Pin O D 12 994 13 000 0 5116 0 5118 12 954 0 5100 Piston rings Ring width Top 0 935 0 950 0 0368 0 0374 0 890 0 0350 Second 0 975 0 990 0 0384 0 0390 0 930 0 0366 Oil 2 380 2 460 0 0937 0 9685 2 370 0 0933 Ring side clearance Top 0 055 0 089 0 0022 0 0035 0 190 0 0075 Second 0 015 0 049 0 0006 0 0019 0 15 0 006 Oil 0 045 0 144 0 0018 0 0057 0 240 0 0094 Ring end gap T...

Page 11: ...kcase cover bolt M8 x 1 25 24 2 4 18 Cylinder bolt M8 x 1 25 24 2 4 18 Spark plug M14 x 1 25 20 2 15 Connecting rod bolt M7 x 1 0 12 1 2 9 Valve adjusting lock nut M5 x 1 0 8 0 8 5 9 Valve lifter bolt M6 x 1 0 10 1 0 7 Oil extension bolt M6 x 1 0 12 1 2 9 Governor holder shaft bolt M6 x 1 0 12 1 2 9 Fuel cock screw M5 x 0 8 5 0 5 3 7 Air cleaner case nut M6 x 1 0 8 5 0 9 6 3 Recoil starter bolt M6...

Page 12: ... 5 5 40 Flange bolt and nut 5 mm 5 5 0 6 4 1 6 mm 12 1 2 9 8 mm 24 2 4 18 10 mm 40 4 1 30 CT Cutting threads flange bolt Retightening 6 mm 12 1 2 9 ITEM TOOL NAME TOOL NUMBER APPLICATION 1 Carburetor float level gauge 07401 0010000 Carburetor float level inspection 2 Valve adjustment wrench 3 mm 07908 KE90200 Valve clearance adjustment 3 Jet cleaner 07JPZ 001010B Cleaning carburetor jets 4 Alcohol...

Page 13: ... SUN EEP V503A Compression test 3 Spring scale SAMIN25MRP Roll back force 4 Flywheel puller OTC 1035 Flywheel removal 5 Combustion chamber brush Cleaning combustion chamber 6 Digital multimeter FLU 88 Electrical component testing 7A Valve seat cutter 31 NWY CU 115 Valve seat reconditioning 7B Valve seat cutter 45 NWY CU 122 7C Valve seat cutter 60 NWY CU 111 7D Solid pilot bar 5 50 mm NWY PM 10055...

Page 14: ... spark plug and inspect P 3 9 Good spark No or weak spark Compression is above 80 psi Install a compression gauge in the spark plug hole P 2 12 Use the recoil starter to briskly crank the engine several times Install the spark plug in the plug cap and perform the spark test P 2 12 Remove disassemble P 8 2 and clean the carburetor P 8 9 Check the choke butterfly with the engine cold Choke closed Co...

Page 15: ...eplace if necessary P 11 7 Less than 12 7 V OK Check the 30 A fuse P 11 7 Turn the key to the START position and check the voltage from the red wire at the starter motor to engine ground Move the negative probe to the oil pan and retest If voltage is now greater than 12 7 V check the starter motor ground wire and connector P 11 7 Inspect replace the starter motor P 9 13 Check the battery voltage T...

Page 16: ...e battery Dirty or stuck Go to CLEANING AND INSPECTING THE PINION DAMPER ASSEMBLY on page 9 13 Remove the starter motor and check if the pinion is stuck or contaminated with grease or oil P 9 13 Check the negative terminal connector and ground wire If pinion engages flywheel less than 9 0 V If pinion does not lift and engage the flywheel less than 10 5 V Check the cranking voltage at the starter m...

Page 17: ...6320 VH7 UA1 charger Allow to rest for 1 hour and retest Check battery connections P 11 6 With the engine running check the charge coil output current P 9 11 Start the engine and verify the speed is 2950 3100 rpm P 3 17 Replace the ignition charge coil P 9 3 Reset the air gap to 0 3 mm and check the charge coil output More than 0 5 mm Less than 0 23 A OK Inspect the charge wire red Replace the fus...

Page 18: ...ge such as a bent crankshaft Retighten or replace P 4 2 Adjust P 3 16 Inspect P 3 16 Replace P 4 2 Inspect P 3 16 Replace P 4 2 Adjust P 3 16 Defective brake plate return spring Roto Stop cable too loose or damaged Clutch spring too weak or clutch lining excessively worn Brake lining excessively worn Roto Stop cable too tight or seized Blade control lever does not return when released or its opera...

Page 19: ...g this test 1 Turn the fuel valve lever to the OFF position and then drain the gasoline from the carburetor 2 Disconnect the spark plug cap from the spark plug 3 Remove the spark plug using a spark plug wrench 4 Pull the recoil starter several times to expel unburned gasoline 5 Attach the spark plug to the spark plug cap and ground the side electrode against the cylinder head bolt 6 Have an assist...

Page 20: ...ition and tilt the mower on its side so the carburetor is up 2 Disconnect the spark plug cap and remove the spark plug P 3 9 3 Remove the Roto Stop assembly P 4 3 4 Remove the four 8 x 10 mm flange bolts and the front shutter holders 5 Remove the two front 5 16 24 x 2 3 8 inch engine mounting bolts Dimension Measurement A 152 4 mm 6 00 in B 127 8 mm 5 031 in C 12 3 mm 0 485 in D 12 7 mm 0 5 in E 5...

Page 21: ... the crankshaft 9 Zero the indicator and position the pointer on the crankshaft as shown 10 Pull the blade control lever against the handlebar and use the 10 x 24 mm blade holder drive pulley bolt to rotate the crankshaft Record the runout If the crankshaft runout exceeds the service limit replace the crankshaft Crankshaft runout Service limit 0 20 mm 0 008 in FABRICATED BASE PLATE BOLTS 5 16 24 x...

Page 22: ...e choke control Replace the carburetor P 8 2 Start the engine and check to see if the choke opens within 3 minutes Opens too slowly or does not open Allow the engine to cool Push the choke valve open and release it The choke should open smoothly and snap closed when released Hard to move Replace the carburetor assembly P 8 2 and the spark plug P 3 9 CHOKE CONTROL ASSEMBLY THERMOWAX ASSEMBLY CHOKE ...

Page 23: ...LE IN APPROVED MANNER Directions Step 1 Add water to the water line Step 2 Add gasoline to the gasoline line Step 3 Replace cap and shake vigorously Step 4 Stand vial vertically with cap upright Let stand for 10 minutes Step 5 If bubbles remain lightly tap vial to disperse bubbles for better accuracy Step 6 Locate the gasoline water separation line and read scale The separation line will indicate ...

Page 24: ...er forward You should hear a clicking noise from the wheel ratchets and the transmission axle should not rotate Pull the lawn mower backwards There should not be any clicking noise from the wheel ratchets and the transmission axle should rotate forward opposite the wheels If either condition does not exist inspect repair the wheel ratchets With the drive clutch lever engaged and the shift lever in...

Page 25: ...e clutch lever This problem is usually caused by vibration transmitted through the cable and handle due to low transmission fluid level A growling noise is usually heard from the transmission Hold the lever in the fast position and perform the ground speed tests shown on P 2 25 If the time is less than 5 7 seconds new unit specification the fluid is not low and the problem is in the shift lever li...

Page 26: ...ed in the correct position Check the position of the control arm spring The tab on the control arm must cover at least two spring coils If necessary position a screwdriver between the case and spring and push it out against the control arm Engage and release the control arm several times to allow the spring to settle to its final position and reconfirm that the tab covers at least two coils CONTRO...

Page 27: ...ling washer and retorque If the leak exists at the input shaft seal remove the pulley and measure the input shaft radial side to side play at the end of the input shaft perpendicular to the axle using a dial indicator and magnetic base Support the transmission in a vise as shown If the play exceeds the service limit the HST will require replacement Service limit 0 4 mm 0 016 in Note 1 2 mm of vert...

Page 28: ...luid from the transmission Transmission fluid will darken during use and may appear to contain fine metallic particles or residue However dark gray oil with metallic residue is considered normal and does not indicate excessive wear or an internal failure 5 Install a 10 mm flange nut on the input shaft Engage the control arm and use a wrench to rotate the pump shaft 3 5 turns clockwise as shown 10 ...

Page 29: ...Hydrostatic Fluid Use only Honda Hydrostatic Fluid P N 08208 HST01 Do not use hydraulic or automatic transmission fluid Be careful not to allow dirt to enter the transmission 9 Rotate the axle shaft 4 5 turns in the direction shown to bleed air from the hydrostatic motor and add Honda Hydrostatic Fluid if necessary 10 Temporarily reinstall the diaphragm and cap with the vent hole positioned as sho...

Page 30: ...the diaphragm and cap so the vent hole is positioned as shown 15 Rotate the input shaft again while repeatedly engaging and releasing the control arm Confirm that the axle rotates when the control arm is engaged and stops when the control arm is released 16 Install the driven pulley Be sure to install the washer first as shown Install and tighten the pulley nut to the specified torque TORQUE 26 29...

Page 31: ...k the engine speed with the throttle set to the FAST position i If the engine speed is not within specification bend the governor spring arm very slightly as needed Left increases spring tension and engine speed Right decreases spring tension and engine speed j Check the drive clutch cable adjustment DRIVE CLUTCH CABLE ADJUSTMENT a With the engine stopped position the cable ties as shown on P 2 26...

Page 32: ...urements to obtain an average 6 Check the transmission operation under load a Position the lawn mower on a smooth concrete surface b Move the shift lever in the fastest position and engage the drive clutch lever c Hold the lawn mower back and confirm the tires rotate slip on the concrete d If the ground speed is too slow and or the wheels stop under load first check the control arm for binding see...

Page 33: ...le Position the cable ties in the locations shown using the handlebar pivot bolt as a starting point for your measurements Adjust and tighten the cable ties Trim off any remaining tail from each cable tie and then rotate the cable ties so that the head and cut edge are facing down Location Distance from pivot bolt 150 mm 5 7 8 in 140 mm 5 1 2 in 400 mm 17 3 4 in CABLE TIE 2 PIVOT BOLT CABLE TIE Se...

Page 34: ...ndle stay HARNESS BAND STARTER MOTOR POSITIVE TERMINAL WHITE WIRE IGNITION COIL GROUND WIRE BLACK STARTER HARNESS SPARK PLUG WIRE CHARGE COIL WIRE WHITE WIRE CHARGE COIL built into ignition coil IGNITION COIL KEY SWITCH AND BATTERY GROUND BLACK WIRE STARTER MOTOR NEGATIVE TERMINAL BLACK WIRE STARTER MOTOR BATTERY CHARGER CONNECTOR CABLE TIE Secure the three starter motor wires to the starter motor...

Page 35: ...2 28 SERVICE INFORMATION HRX217HYA HRX217HZA NOTES ...

Page 36: ...NE UP SPECIFICATIONS 3 3 13 FUEL TANK AND FILTER 3 11 4 REAR SHIELD 3 4 14 VALVE CLEARANCE 3 12 5 BLADES 3 4 15 PINION GEAR 3 13 6 ENGINE OIL 3 6 16 ADJUSTING ARM BUSHING 3 14 7 AIR FILTER 3 7 17 THROTTLE CABLE AND LINKAGE 3 15 8 GRASS BAG 3 8 18 DRIVE CLUTCH CABLE 3 15 9 SPARK PLUG INSPECTION 3 9 19 ROTO STOP 3 16 10 SPARK ARRESTER CLEANING 3 9 20 GOVERNOR 3 17 ...

Page 37: ...f use or every two years See page Rear shield Check O 3 4 Blades Inspect O 3 4 Blade mounting bolts Inspect O 3 4 Engine oil Check O 3 6 Change O O 1 O O 3 6 Air filter Check O 3 7 Clean O 2 O 2 O 2 Replace O Grass bag Check O 3 8 Blade control operation Check O O 3 10 Blade control cable Adjust O 3 16 Spark plug Check O 3 9 Replace O Spark arrester optional part Clean O 3 9 Throttle cable Adjust ...

Page 38: ...aft is rotated fully clockwise at full throttle P 3 17 Drive clutch cable Adjust so the mower begins to self propel when the shift lever is moved one or two notches forward and can roll backward when the drive clutch lever is released P 3 15 Roto Stop Cable Adjust for 10 15 mm 3 8 9 16 in free play at edge of lever P 3 16 Mechanism Brake wear service limit 1 5 mm 0 59 in minimum Clutch wear servic...

Page 39: ... carburetor is up 4 Inspect the blades for damage cracks and excessive wear rust or corrosion 5 Dull blades can be sharpened but blades that are worn out bent cracked or otherwise damaged must be replaced REMOVAL INSTALLATION 1 Turn the fuel valve to the OFF position disconnect the spark plug and tilt the mower on its right side 2 Remove the two blade bolts and special washers from the blade contr...

Page 40: ...ofile removing material from the blade tip never the inner end of the cutting surface NOTICE Grinding or filing a step in the blades can create a weak point causing cracks to develop in the blades during mower operation Maintain the original bevel angle 30 40 while sharpening Do not alter the angle Remove equal amounts of material from both cutting edges to preserve symmetry and balance 2 After sh...

Page 41: ...eclamation Do not throw it in the trash or pour it on the ground or down a drain 4 Refill with the recommended oil to the upper limit mark on the dipstick Check oil level with the mower on a level surface and the dipstick fully inserted but not screwed in 5 Oil is a major factor affecting performance and service life SAE 10W 30 is recommended for general use Other viscosities shown in the chart ma...

Page 42: ...t seals and performs as designed 1 Press the latch tabs on the top of the air cleaner and remove the air cleaner cover 2 Remove the paper filter from the air cleaner housing 3 Inspect the filter and replace it if it is damaged 4 Clean the filter Tap the filter several times on a hard surface to remove dirt or blow with compressed air not exceeding 207 kPa 30 psi through the filter from the inside ...

Page 43: ...e replacement bag or its equivalent 1 Unclip the plastic edges of the bag from the frame 2 Remove the bag from the frame 3 Insert the frame into the replacement bag as shown 4 Clip the plastic edges of the bag onto the frame as shown Assemble the grass bag frame by pulling the support legs outward and sliding them into the eyelets as shown BAG PLASTIC EDGE FRAME PLASTIC EDGE BAG FRAME HANDLE EYELE...

Page 44: ...t be serviced every 100 hours to keep it functioning as designed Allow the engine to cool before proceeding with this procedure 1 Allow the engine to cool 2 Unclip the two red top cover tabs 1 on the muffler side of the engine and then slightly lift the red top cover up to expose the upper muffler shield bolt page 7 1 3 Remove the three bolts 2 from the muffler shield 3 using a 10 mm socket wrench...

Page 45: ...ave been installed in the cylinder Do not press the cleaning brush with force against the combustion chamber 12 BLADE CONTROL OPERATION CHECK Start the engine outdoors Move the throttle to the FAST position Operate the Roto Stop The blades should engage when you pull the lever to the handlebar and the blades should stop quickly when you release the lever TOOL Cleaning brush Commercially available ...

Page 46: ...strainer into the fuel tank fitting 8 Connect the fuel tube to the fuel tank fitting 9 Position the fuel tube clip over the fuel tank fitting After assembly check for fuel leaks FUEL TUBE INSPECTION 1 Check the fuel tubes for deterioration cracks or signs of leakage Replace the fuel tubes if necessary 2 To replace the fuel tubes drain the fuel into a suitable container 3 Replace the fuel tubes wit...

Page 47: ...ge between the valve adjusting screw and valve stem to measure the valve clearance If adjustment is necessary proceed as follows ADJUSTMENT 1 Hold the valve adjusting screw using the special tool 3 mm wrench and loosen the valve adjusting screw lock nut 2 Turn the adjusting screw to obtain the specified clearance 3 Hold the valve adjusting screw and retighten the valve adjusting screw lock nut to ...

Page 48: ...sure NLGI 2 GC LB grease or equivalent to the axle pinion gear ratchet spring and ratchet key IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lithium silicone WD 40 or any other spray lubricant 7 Reassemble in the reverse order of disassembly and as noted 3 mm SPACER...

Page 49: ...ing a Scotch Brite pad 15 Thoroughly apply a coat of Honda Marine extreme pressure NLGI 2 GC LB grease or equivalent to the bushing and seal and then reinstall the adjuster assembly and secure with the washer and circlip IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize whit...

Page 50: ...ngine speed 18 DRIVE CLUTCH CABLE 1 With the engine stopped position the cable ties as shown on P 2 26 2 Pull the shift lever all the way back to the neutral position 3 Start the engine and move the throttle lever to the FAST position 4 Engage the drive clutch lever and confirm the following a Mower does not self propel b Mower begins to self propel or creeps very slowly for ward when the shift le...

Page 51: ...vice limit replace the driven disc and inspect the clutch spring P 4 2 If the clutch spring is not within specifications replace the clutch spring P 4 4 BRAKE WEAR With the blade control lever released measure the distance between the edge of the brake plate and the indicator Replace the disc if below the service limit Blades have been removed for clarity CLUTCH WEAR With the blade control lever p...

Page 52: ...to Stop lever and check the maximum engine speed 8 If adjustment is necessary bend the governor spring tab on the fuel valve plate very slightly Moving the tab to the left decreases governor spring tension and engine speed Moving the tab to the right increases governor spring tension and engine speed DANGER The mower blades will rotate during this procedure Rotating blades will amputate fingers ha...

Page 53: ...3 18 MAINTENANCE HRX217HYA HRX217HZA NOTES ...

Page 54: ...4 1 4 ROTO STOP DRIVE BELT 1 ROTO STOP 4 2 2 DRIVE BELT 4 10 ...

Page 55: ...starting with an L identifies the disc is for an HRX K6 model BALL PLATE SPRING BLADE HOLDER SPRING HOOK PLATE STEEL BALL 3 DRIVE PULLEY WOODRUFF KEY Install in lower keyway slot BEARING Replace if it doesn t rotate smoothly CLUTCH SPRING UP mark towards engine INSPECT P 4 6 BEARING Replace if it doesn t rotate smoothly BRAKE PLATE SPECIAL BLADE HOLDER BOLT SPRING INSPECT P 4 6 ...

Page 56: ... throttle control 6 Disconnect the Roto Stop inner cable from the ball plate by pushing the inner cable up the cable housing If the inner cable will not move freely inspect the Roto Stop cable and lubricate or replace as necessary 7 Wrap the tips of needle nose pliers with tape to prevent damaging the clutch spring Use needle nose pliers and lift the spring hook off the upper anchor point then rem...

Page 57: ... disc Rotate the crankshaft so that the crankshaft keyway is up 9 Remove the drive disc but do not remove the key from the crankshaft 10 Slide the brake assembly off the crankshaft and leave the transmission drive pulley in place INSPECTION 1 Inspect the drive disc for discoloration from overheating and excess wear BLADE HOLDER DRIVEN DISC CLUTCH SPRING 10 x 24 mm HEX BOLT DRIVE DISC KEY BRAKE ASS...

Page 58: ...r If the driven disc is washed with parts cleaner the driven disc will require replacement 3 Disassemble the brake assembly a Push the spring hook plate down b Rotate the spring hook plate clockwise c Release the three hooks d Separate the brake plate from the ball plate and remove the three balls 4 Inspect the ball plate spring for damage or deformation such as bending or cracks BRAKE ASSEMBLY SP...

Page 59: ...smooth operation Replace any damaged bearings When installing the bearings be sure to only press on the outer bearing race during installation 7 Check the clutch spring for abnormal wear or damage Replace the spring if any abnormal wear is found Make sure the spring contains a rubber tube inside of it This rubber tube is required for vibration dampening Service limit Clutch spring 6 8 mm 0 27 in C...

Page 60: ...by pushing down and rotat ing the spring hook plate counterclockwise to lock all three hooks in place Make sure all three spring hooks are secured e Rotate the brake plate and confirm that it moves smoothly and springs back 9 Inspect the Roto Stop cable for evidence of binding or sticking Replace the cable if any sticking or binding is found INSTALLATION 1 Align the brake assembly hole with the st...

Page 61: ...ng the engine Install the driven disc into the blade holder with the metal surface facing the clutch spring 4 Install the blade holder clutch spring and driven disc as an assembly Hold the flywheel nut with a 19 mm socket and ratchet and then tighten the 10 x 24 mm hex bolt TORQUE 49 59 N m 36 43 ft lb DRIVE DISC KEY BLADE HOLDER DRIVEN DISC CLUTCH SPRING ENGINE BLADE HOLDER CLUTCH SPRING DRIVEN D...

Page 62: ... clamp or contact the spring coils during installation Be careful not to damage or bend the spring 7 Attach the Roto Stop cable to the ball plate 8 Attach the Roto Stop cable to the throttle control and adjust the blade control lever free play P 3 16 9 Install the blades rear scroll P 12 4 and fan cover P 7 3 and top cover P 7 1 10 Be sure the curved washers securing the blades are installed corre...

Page 63: ...om the Roto Stop assembly 6 Insert a screwdriver or rod in the hole in the transmission cable bracket Pivot the transmission as shown and remove the belt from the driven pulley Remove the belt INSTALLATION Installation is done in the reverse order of removal Be sure the belt is positioned in the drive pulley before applying tension to the belt During installation make sure the guide rib on the top...

Page 64: ...Disconnect the throttle cable at the engine 8 Position a screwdriver or rod in the hole in the transmission cable bracket Pivot the transmission as shown and remove the belt from the driven pulley 9 Remove the drive belt 10 Remove the drive pulley from the crankshaft 11 Remove the woodruff key from the outer groove 1 ENGINE 5 1 THROTTLE CLAMP SCREW THROTTLE CABLE Attach under screw on lower side o...

Page 65: ... two remaining 5 16 24 x 2 3 8 inch engine mounting bolts and the front base plate 14 Remove the engine INSTALLATION Installation is done in the reverse order of removal Tighten the engine mounting bolts to the specified torque TORQUE 19 6 23 6 N m 14 5 17 4 ft lb TABS ROTO STOP CABLE FRONT BASE PLATE BOLT 5 16 24 x 2 3 8 in 2 19 6 23 6 N m 14 5 17 4 ft lb ...

Page 66: ...6 1 6 MUFFLER 1 REMOVAL INSTALLATION 6 2 6 ...

Page 67: ...ROTECTOR 6 x 79 mm BOLT CT bolt 2 4 x 6 mm SCREW optional part Use a plastic hammer to loosen carbon deposits from the muffler and then remove carbon deposits from muffler If the seal flange is dented or damaged replace the muffler Check the cylinder barrel exhaust port for damage Do not tap on the muffler seal flange and do not damage this part MUFFLER SEAL FLANGE EXHAUST PORT SPARK ARRESTER opti...

Page 68: ...OIL STARTER 1 TOP COVER REMOVAL INSTALLATION 7 2 4 RECOIL STARTER INSPECTION 7 5 2 RECOIL REMOVAL INSTALLATION 7 3 5 RECOIL STARTER ROPE REPLACEMENT 7 5 3 FAN COVER REMOVAL INSTALLATION 7 4 6 REEL UNWOUND 7 7 7 ...

Page 69: ...d through the hole in the top cover Reattach the starter grip to the handlebar TOP COVER FUEL TANK CAP SPRING NUT 5 x 8 mm SCREW TANK MOUNT RUBBER A REMOVAL Loosen the screw and then remove the spring nut FAN COVER TAB MOUNTS TABS 2 per side STARTER GRIP INSTALLATION Attach the fuel tank cap tether into the hole in the top cover The tether end has a flat portion that must be slid through the slot ...

Page 70: ...7 3 HRX217HYA HRX217HZA RECOIL STARTER 2 RECOIL REMOVAL INSTALLATION Remove the top cover P 7 2 6 x 14 mm BOLT 3 8 5 N m 6 3 ft lb RECOIL STARTER ...

Page 71: ...e top cover P 7 2 and then reinstall the fuel tank cap to prevent dirt or debris from entering the fuel tank The recoil starter assembly does not need to be removed to remove the fan cover Reassembly is the reverse order of removal FAN COVER 6 x 23 mm BOLT 5 CT type cutting threads ...

Page 72: ... 7 3 2 Check the operation of the ratchets by pulling the starter rope out several times 3 Check the tabs on the cooling fan for damage 5 RECOIL STARTER ROPE REPLACEMENT 1 Remove the recoil starter P 7 3 2 Pull the starter rope until the starter rope is pulled out fully RATCHETS TABS STARTER ROPE ...

Page 73: ...arter grip and make a slip knot at the end of the rope 6 Pass the other end of the starter rope through the rope hole in the starter case and through the rope hole in the starter reel and make a slip knot at the end of the rope 7 Remove the band holding the starter reel and carefully allow the starter reel to rewind 8 Check the operation of the ratchets by pulling the starter rope several times 9 ...

Page 74: ...ke a slip knot at the end of the rope 4 Pass the other end of the starter rope through the rope hole in the starter case then through the rope hole in the starter reel and make a slip knot at the end of the rope 5 Remove the band holding the starter reel and carefully allow the starter reel to rewind 6 Check the operation of the ratchets by pulling the starter rope several times Starter reel turns...

Page 75: ...7 8 RECOIL STARTER HRX217HYA HRX217HZA NOTES ...

Page 76: ...8 1 8 FUEL SYSTEM 1 AIR CLEANER CARBURETOR 8 2 3 FUEL TANK 8 14 2 CONTROL BASE GOVERNOR ARM 8 5 4 FUEL TUBE 8 15 ...

Page 77: ...SKET INSULATOR GASKET CARBURETOR GASKET FUEL TUBE INSTALLATION Insert into the breather hole in the top crankcase cover Be sure it is properly seated in the hole If not connected properly dirt ingestion and engine damage will occur INSTALLATION Hook the governor rod in the larger hole in the carburetor throttle valve Hook the throttle return spring in the smaller hole in the carburetor throttle va...

Page 78: ... center pin extends b Screw a No 6 sheet metal or drywall screw into the thermowax body and then carefully pry the thermowax out b Use the side of the cylinder as a prying surface as shown Do not pry against the intake port gasket sealing surface Use a small scraper brake cleaner and compressed air to remove the remaining sealant from the cavity c Remove as much sealant as possible especially from...

Page 79: ...e correct direction to ensure the gasket aligns with the port 4 Carburetor 5 Air cleaner gasket Be sure the vent hole in the air cleaner gasket aligns with the hole in the carburetor 7 Install the crankcase breather tube so that the paint mark is even with the side plate Ensure the tube is securely inserted into the hole in the crankcase and onto the air cleaner case NOTICE Failure to properly con...

Page 80: ...OVERNOR ARM NUT 3 N m 2 2 ft lb min FUEL VALVE B12 TUBE CLIP B8 TUBE CLIP BOLT CT bolt 6 x 14 mm CONTROL BASE FUEL TUBE GOVERNOR ARM INSTALLATION Install the governor rod through the throttle return spring as shown Connect each to the governor arm and carburetor throttle arm as shown GOVERNOR ARM THROTTLE RETURN SPRING THROTTLE ARM GOVERNOR ROD GOVERNOR ARM THROTTLE RETURN SPRING 12 N m 9 ft lb PA...

Page 81: ... 4 x 12 mm WASHER 4 mm ENGINE STOP SWITCH INSPECTION P 9 5 CABLE HOLDER SCREW 5 x 16 mm LEVER SPRING CONTROL LEVER RETURN SPRING CONTROL BASE WIDE TERMINAL to stop switch wire NARROW TERMINAL not used CABLE HOLDER SCREW 5 x 16 mm LEVER SPRING CONTROL LEVER RETURN SPRING CONTROL BASE ...

Page 82: ...e the access screw to clean the pilot air jet ASSEMBLY Before installing clean thoroughly with low pressure compressed air max 30 psi MAIN JET NUMBER 70 SET GASKET FLOAT PIN 5 x 6 mm ACCESS SCREW MAIN NOZZLE ASSEMBLY Before installing clean thoroughly with low pressure compressed air MAIN JET ASSEMBLY Before installing clean thoroughly with low pressure compressed air max 30 psi SET BOLT FLOAT CHA...

Page 83: ...ter cap must be installed NOTICE Tampering is a violation of federal and California law 1 When the limiter cap has been broken off remove the broken pilot screw 2 Place the spring on the replacement pilot screw and install it on the carburetor 3 Turn the pilot screw in until it is lightly seated then turn the screw out the required number of turns 4 Apply Loctite 638 to the inside of the limiter c...

Page 84: ...rburetor cleaner and compressed air Inspect the carburetor body throttle and choke levers and pilot screw including limiter cap for damage If any damage exists carburetor replacement may be necessary 2 Remove the set bolt float chamber float pin float valve and float Clean and then inspect the float valve tip for damage and replace if necessary 3 Remove the main jet and the main nozzle With the ma...

Page 85: ...Cleaning only with carburetor cleaner and compressed air may not be enough to fully remove contaminants inside the jet nozzle NOTICE Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor Never force a needle and never use a needle with a bent or damaged tip 7 Clean the main jet by spraying carburetor cleaner through the jet and using the appropriate size j...

Page 86: ...d compressed air The passage is small and easily obstructed so repeat several times It is not necessary to remove the pilot screw at this point IMPORTANT It is vital to use the jet cleaning tool to remove stubborn debris Cleaning only with carburetor cleaner and compressed air may not be enough to fully remove contaminants inside the pilot jet 10 Clean the high speed air passage with carburetor cl...

Page 87: ...bstructions Spray carburetor cleaner through the slow speed air passage From the opposite end confirm that a steady stream of carburetor cleaner sprays out from around the pilot screw tip and transition ports If it does not flow around the pilot screw tip remove the pilot screw and clean the passage The pilot screw must be destroyed and replaced if it is removed It may be more cost effective to re...

Page 88: ...ve float and float chamber Make sure the float valve is properly attached to the float Ensure the float chamber is installed correctly making a good seal with the gasket 17 Reinstall the carburetor on the engine turn the fuel valve on and check for fuel leaks 18 Start the engine and allow it to warm up for several minutes Check the maximum no load engine speed ...

Page 89: ... You can be burned or seriously injured when handling fuel Stop the engine and let it cool Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately TANK MOUNT RUBBER A FUEL TANK TANK MOUNT RUBBER B TANK MOUNT RUBBER A FUEL TANK CAP CLEANING Clean with solvent FUEL STRAINER FUEL TUBE TUBE CLIP 6 x 14 mm BOLT 2 FUEL TANK STAY CHECK Check for deterioration or cracks INSTAL...

Page 90: ...d off the fuel valve with a tool the fuel valve may become damaged 4 Connect the fuel tube to the fuel valve 5 Position the fuel tube clip over the fuel valve fitting 6 Remove the fuel tube clamp and return the fuel valve to the ON position 7 Check for fuel leaks and repair as necessary FUEL TUBE AND CLAMP CHANGES All Honda Power Equipment manufactured after January 1 2009 uses low permeable fuel ...

Page 91: ...8 16 FUEL SYSTEM HRX217HYA HRX217HZA NOTES ...

Page 92: ...9 1 9 FLYWHEEL IGNITION COIL 1 IGNITION COIL 9 2 3 SIDE PLATE 9 10 2 FLYWHEEL 9 7 4 ELECTRIC STARTER HZA ONLY 9 11 ...

Page 93: ...HRX217HYA HRX217HZA 1 IGNITION COIL REMOVAL INSTALLATION HYA TYPE Remove the fan cover page 7 4 After installation adjust the ignition coil air gap page 9 5 IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTOR 6 x 23 mm BOLT 2 ...

Page 94: ... HZA TYPE Remove the fan cover P 7 3 Disconnect the stop switch cord and charge coil connectors After installation adjust the ignition coil air gap P 9 5 IGNITION COIL SPARK PLUG CAP STOP SWITCH CORD CONNECTOR 6 x 23 mm BOLT 2 CHARGE COIL CONNECTOR ...

Page 95: ... engine by pulling the recoil starter and check whether sparks jump across the electrode INSPECTION IGNITION COIL HYA TYPE Remove the ignition coil page 9 2 Primary Side Resistance Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coils primary terminal while touching the other test lead to the iron core Secondary Side Resistance Attach an ohmmeter lead betw...

Page 96: ...lunger is released Replace the engine stop switch if the correct continuity test results are not obtained IGNITION COIL AIR GAP ADJUSTMENT Adjustment is required only when the ignition coil or flywheel has been removed Remove the fan cover page 7 3 Attach the ignition coil and leave the bolts slightly loose Insert a long 0 3 mm thick feeler gauge between the ignition coil and the flywheel and push...

Page 97: ...D DIODE TEST HZA TYPE ONLY 1 Select the diode function of a digital multimeter 2 Attach the red lead to the laminate core ground and the black lead to the charge coil terminal 3 Check for the specified voltage drop Specified voltage 0 4 0 8 VDC 0 30 0 50 mm 0 012 0 020 in 0 30 0 50 mm 0 012 0 020 in IGNITION COIL DIODE TEST FUNCTION RED TEST LEAD BLACK TEST LEAD CHARGE COIL TERMINAL DIGITAL MULTIM...

Page 98: ...BLY REASSEMBLY 1 Remove the fan cover P 7 3 2 Remove the ignition coil P 9 2 75 N m 55 ft lb FLYWHEEL NUT 14 mm INSTALLATION When installing the flywheel check to be sure that the woodruff key remains in its slot in the crankshaft FLYWHEEL WOODRUFF KEY HYA type shown ...

Page 99: ...ommercially available 6 inch flywheel puller on the flywheel with one of the puller jaws under the magnets at the PULLER marks Set a shop towel or equivalent cloth between the flywheel and puller Tighten the flywheel puller and then tap the end of the puller with a heavy brass hammer to remove the flywheel NOTICE Do not use an impact wrench when removing the flywheel The flywheel is aluminum and i...

Page 100: ...ruff key is set in the keyway properly 2 Install the flywheel 3 Apply engine oil to the flywheel nut threads 4 Holding the flywheel with a commercially available strap wrench tighten the 14 mm special nut to the specified torque TORQUE 75 N m 55 ft lb 5 Install the ignition coil P 9 2 6 Install the fan cover P 7 3 and top cover P 7 1 SPECIAL NUT 14 mm STRAP WRENCH commercially available 75 N m 55 ...

Page 101: ...OIL HRX217HYA HRX217HZA 3 SIDE PLATE REMOVAL INSTALLATION Remove the flywheel P 9 7 BOLT 6 x 14 mm 2 SIDE PLATE STOP SWITCH CORD HYA type only INSTALLATION Connect to the wide terminal of the engine stop switch HYA type shown ...

Page 102: ...cranking voltage drops below 9 0 VDC charge the battery for 24 hours 7 After charging the battery check the cranking voltage again If the proper cranking voltage still cannot be obtained replace the battery CHARGE COIL OUTPUT CHECK The battery must be partially discharged prior to performing this test If the battery voltage is 12 7 V disconnect the spark plug and crank the electric starter several...

Page 103: ...ew and the black wire from the starter motor 5 Remove the white wire and black wire from the bottom of the starter motor 6 Remove the two 6 mm special bolts and the starter motor It is not necessary to remove the flywheel when removing the starter motor only 7 Install in the reverse order of removal 5 x 8 mm PAN SCREW WHITE WIRE BLACK WIRE BLACK WIRE CABLE TIE STARTER MOTOR INSPECTION P 9 13 6 mm ...

Page 104: ...te the pinion rubber damper from the drive plate Using your thumbs push the pinion vertically on the shaft in the direction shown Do not rotate the pinion assembly 2 Thoroughly clean between the drive plate and damper using a rubber compatible contact cleaner or brake cleaner Use a cotton swab or other utensil to remove any residue from the damper rubber and drive plate Do not use compressed air t...

Page 105: ... drive plate Make sure the damper rubber seal lip is properly positioned and seated around the drive plate 6 Rotate the pinion clockwise as shown to verify that the pinion and drive plate assembly climb up the shaft 7 Reinstall the starter motor and test for proper operation After cleaning make sure the rubber seal lip is properly positioned around the drive plate Pinion and drive plate assembly s...

Page 106: ...HER COVER REMOVAL INSTALLATION 10 3 7 CYLINDER COMPRESSION CHECK 10 11 8 GOVERNOR REMOVAL INSTALLATION 10 12 3 CYLINDER REMOVAL INSTALLATION 10 4 9 OIL FILLER CAP EXTENSION REMOVAL INSTALLATION 10 13 4 CYLINDER HEAD DISASSEMBLY ASSEMBLY 10 7 10 CAMSHAFT CYLINDER PISTON VALVE INSPECTION 10 14 5 CRANKSHAFT CAMSHAFT PISTON REMOVAL INSTALLATION 10 8 10 ...

Page 107: ...river or equivalent tool into the recesses as shown and remove the crankcase cover REMOVAL Carefully remove with a screwdriver at the pry points P 10 2 INSTALLATION Thoroughly clean both surfaces and then apply a bead Ø 1 0 2 0 mm Ø 0 04 0 08 in of liquid gasket Hondabond HT Loctite 5900 or equivalent 24 N m 18 ft lb 8 x 25 mm BOLT 6 DOWEL PIN 2 CRANKCASE COVER Apply grease to the lips OIL SEAL 28...

Page 108: ...10 3 HRX217HYA HRX217HZA CAM PULLEY CRANKSHAFT PISTON CYLINDER 2 BREATHER COVER REMOVAL INSTALLATION Remove the crankcase cover P 10 2 6 x 14 mm BOLT BREATHER COVER 5 x 8 mm SCREW BREATHER VALVE ...

Page 109: ...e 3 6 Remove the following Crankcase cover page 10 2 Carburetor page 8 2 Muffler page 6 2 Rocker arms and push rods page 10 7 REMOVAL Insert a screwdriver or equivalent tool into the recesses 1 as shown and carefully pry to remove the cylinder from the crankcase 24 N m 18 ft lb 8 x 40 mm BOLT 2 8 x 25 mm BOLT 2 CYLINDER HEAD 1 ...

Page 110: ...recheck the valve clearance page 3 12 Install the camshaft and lifters before installing the cylinder page 10 8 6 x 14 mm BOLT 4 CYLINDER HEAD COVER 24 N m 18 ft lb 8 x 40 mm BOLT 2 24 N m 18 ft lb 8 x 25 mm BOLT 2 CYLINDER INSTALLATION P 10 6 Do not reuse if bent or damaged INSTALLATION P 10 6 ...

Page 111: ...proximately 30 minutes after assembly and before filling with oil and starting the engine CYLINDER HEAD COVER INSTALLATION Do not reuse the original cover if it is bent or damaged Clean the mating surfaces of the cylinder head cover and the cylinder using a degreasing cleaning agent or a clean shop towel Apply a bead Ø 1 5 2 5 mm Ø 0 06 0 10 in of liquid gasket Hondabond HT or equivalent to the cy...

Page 112: ...alves will drop into the cylinder 8 N m 5 9 ft lb VALVE ADJUSTING LOCK NUT 2 VALVE STEM SEAL Intake valve only VALVE SPRING 2 INTAKE VALVE EXHAUST VALVE ROCKER ARM 2 ROCKER ARM SHAFT 2 VALVE ADJUSTING SCREW 2 PUSH ROD 2 SPARK PLUG INSTALLATION Install each rocker arm shaft in the direction as shown INSTALLATION The intake and exhaust valves are the same However if the valves are being reused reins...

Page 113: ... of dots 3 CAMSHAFT CRANKSHAFT CONNECTING ROD CAP CONNECTING ROD BOLT 2 12 N m 9 ft lb TIMING GEAR THRUST WASHER PISTON INSPECTION Install the piston through the crankcase so that the FW mark points toward the flywheel side 10 N m 7 ft lb VALVE LIFTER 2 VALVE LIFTER BOLT 2 CRANKCASE 1 2 3 INSTALLATION P 10 9 INSTALLATION If reusing the valve lifters reinstall in their original locations INSTALLATI...

Page 114: ...l aligned CAM TIMING INSPECTION Remove the spark plug and crankcase cover P 10 2 Rotate the crankshaft until the two dots on the timing gear and the two dots on the camshaft align with each other If the dots align the cam timing is set properly If the dots never align the cam timing is incorrectly set To correct the cam timing remove the crankshaft and timing gear from the crankcase and then follo...

Page 115: ...er end with long nosed pliers and rotating the clip in PISTON PIN CLIP 2 ASSEMBLY Chrome plated Do not interchange with the SECOND RING TOP RING OIL RING COMBINATION RING SECOND RING MANUFACTURERS MARK Install with the manufacturers mark facing upward as shown Do not interchange the top ring and the second ring After assembly check for smooth movement of the piston rings Stagger the piston ring en...

Page 116: ...Start the engine and warm up to normal operating temperature Turn the fuel valve lever to the OFF position and then drain the fuel from the carburetor Remove the spark plug cap from the spark plug Remove the spark plug using a spark plug wrench Pull the recoil starter several times to expel unburned gasoline Thread a commercially available compression gauge into the spark plug hole Briskly and rep...

Page 117: ...e pin against the groove in the shaft LOCK PIN GOVERNOR HOLDER SHAFT Before installing check for wear and damage of the gear Check that the weights move freely Be sure to install the governor weight before installing the crankshaft GOVERNOR WEIGHT HOLDER THRUST WASHER GOVERNOR HOLDER CLIP ASSEMBLY Insert firmly into the shaft groove 12 N m 9 ft lb BOLT 6 x 14 mm WASHER GOVERNOR ARM SHAFT ASSEMBLY ...

Page 118: ...LLER CAP EXTENSION REMOVAL INSTALLATION O RING OIL FILLER CAP DIPSTICK OIL FILLER EXTENSION OIL FILLER PACKING 6 x 14 mm SPECIAL BOLT 2 12 N m 9 ft lb INSTALLATION Be sure that no dust or foreign material enters when installing the O ring Be careful not to pinch the O ring ...

Page 119: ...compressor by using a pick tool to move the decompressor weight to the opposite end of the slot and then gently releasing Do not push on the decompressor pin with the pick tool Only push on the decompressor weight It is normal for the decompressor to lock up when pushing on the pin and not the weight Repeat several times If the weight fails to completely return on its own at any time by spring for...

Page 120: ...aft CYLINDER SLEEVE I D Measure and record the cylinder I D at three levels in both the X axis perpendicular to the crankshaft and the Y axis parallel to the crankshaft Take the maximum reading to determine the cylinder wear and taper If the measurement is more than the service limit replace the cylinder Do not hone the cylinder STANDARD 6 000 6 030 mm 0 2362 0 2374 in SERVICE LIMIT 6 043 mm 0 237...

Page 121: ...ond oil as a set PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using feeler gauge If the calculated clearance is more than the service limit replace the piston rings top second oil as a set and recheck the clearance If the clearance is still more than the service limit with the new piston ring replace the piston STANDARD 65 970 65 990 mm 2 ...

Page 122: ...mit replace the piston pin PISTON PIN BORE I D Measure and record the piston pin bore I D of the piston If the measurement is more than the service limit replace the piston PISTON PIN TO PISTON PIN BORE CLEARANCE Subtract the piston pin O D from the piston pin bore I D to obtain the piston pin to piston pin bore clearance If the calculated clearance is more than the service limit replace the pisto...

Page 123: ...ified torque Measure the connecting rod big end I D If the measurement is more than the service limit replace the connecting rod and connecting rod cap CRANKSHAFT MAIN JOURNAL O D Measure the crankshaft main journal O D PTO side Flywheel side If the measurement is less than the service limit replace the crankshaft STANDARD 13 005 13 020 mm 0 5120 0 5126 in SERVICE LIMIT 13 07 mm 0 515 in TORQUE 12...

Page 124: ...urface Place a piece of Plastigauge on the crank pin axially install the connecting rod and the connecting rod cap Apply engine oil to the connecting rod bolt 1 threads and seating surface Tighten the connecting rod bolts to the specified torque Do not rotate the crankshaft while the Plastigauge is in place Remove the connecting rod cap and measure the Plastigauge 1 using a Plastigauge scale 2 If ...

Page 125: ... the service limit replace the crankcase CRANKSHAFT AXIAL CLEARANCE Measure the crankshaft axial play before removing the oil pan crankshaft and piston If the measurement is more than the service limit inspect the thrust washer timing gear crankshaft crankcase and crankcase cover for wear or damage STANDARD 25 420 25 441 mm 1 0008 1 0016 in SERVICE LIMIT 25 466 mm 1 0026 in STANDARD 28 020 28 041 ...

Page 126: ...an the service limit replace the valve spring VALVE FACE VALVE STEM O D Inspect each valve for face irregularities If necessary replace the valve Inspect each valve for bending or abnormal stem wear If necessary replace the valve Measure and record each valve stem O D If the measurement is less than the service limit replace the valve STANDARD 30 5 mm 1 20 in SERVICE LIMIT 29 0 mm 1 14 in SERVICE ...

Page 127: ...seat Insert the valve and snap it closed against its seat several times Be sure the valve does not rotate on the seat The transferred marking compound will show any area of the valve face that is not concentric Measure the valve seat width of the cylinder head If the measurement is more than the service limit recondition the valve seat P 10 23 Check whether the valve seat contact area of the valve...

Page 128: ...service limit recondition the valve seat Check whether the valve seat contact area of the valve is too high If the valve seat is too high recondition the valve seat Prepare a thick paper cylinder or equivalent material with a large enough diameter to fit against the cylinder wall of the cylinder Insert the thick paper into the cylinder to protect the cylinder wall during valve seat reconditioning ...

Page 129: ... into their seats using a commercially available valve lapper and lapping compound After lapping wash all residual compound off the cylinder head and valve Do not push the valve against the seat with force during lapping Apply a light pass with the valve lapper Avoid lapping the valve in the same position as it causes uneven wear Lap the valve by turning the lapper slowly Take care not to allow th...

Page 130: ...move the oil seal Drive a new oil seal 1 in the position as shown using the special tools INSTALLATION HEIGHT 1 0 1 5 mm 0 04 0 06 in TOOLS Bearing driver attachment 62 x 64 mm 2 07947 6340400 Driver handle 3 07749 0010000 INSTALLATION HEIGHT 5 5 6 0 mm 0 22 0 24 in TOOLS Bearing driver attachment 37 x 40 mm 2 07746 0010200 Driver handle 3 07749 0010000 1 0 1 5 mm 0 04 0 06 in 3 2 1 5 5 6 0 mm 0 2...

Page 131: ...10 26 CAM PULLEY CRANKSHAFT PISTON CYLINDER HRX217HYA HRX217HZA NOTES ...

Page 132: ...11 1 11 HANDLE PIPE SHIFT LEVER THROTTLE LEVER 1 HANDLE PIPE 11 2 3 HANDLE STAY 11 5 2 THROTTLE AND SHIFT CONTROL 11 4 4 BATTERY BOX HZA ONLY 11 7 ...

Page 133: ...all through change lever LOCK LEVER HINGE PIN 6 x 30 mm LOCK LEVER COTTER PIN HINGE PIN LOCK PIN 6 mm 2 WASHER 6 mm 2 PLAIN WASHER 8 mm 2 BLADE CONTROL CABLE ARM DRIVE CLUTCH LEVER PIN CLUTCH SPRING RATCHET PUSH ROD HANDLE BLADE CONTROL LEVER RETURN SPRING COLLAR 8 x 11 x 13 5 mm ROPE GUIDE INSTALLATION P 11 3 NYLON LOCK NUT 6 mm 4 8 N m 3 6 ft lb THROTTLE CABLE ADJUSTMENT P 3 15 DRIVE CLUTCH CABL...

Page 134: ...t side handlebar and then loosely install the 6 mm locking nut 2 Rotate the rope guide so that the open end of the pigtail is perpendicular to the handlebar and pointing inward between the two handlebar pipes 3 Fully tighten the 6 mm locking nut while ensuring the rope guide does not rotate from the position set in step 2 4 Slide the starter rope through the small gap in the rope guide pigtail ROP...

Page 135: ... COVER SHIFT LEVER SHIFT LEVER SPRING STOPPER RETURN ARM SPRING PIN 6 x 22 mm SHIFT LEVER COLLAR SELF TAPPING SCREW 5 x 12 mm 2 FLANGE NUT 6 mm PLAIN WASHER 6 mm LOCK PIN 6 mm FLANGE BOLT 6 x 10 mm WASHER HANDLEBAR THROTTLE CABLE ADJUSTMENT P 3 15 DRIVE CLUTCH CABLE ADJUSTMENT P 3 15 CLUTCH LEVER RETURN SPRING SHIFT LEVER ARM Outside hole not used CLUTCH SPRING ...

Page 136: ...E STAY CABLE TIE 3 INSTALLATION P 2 26 ROPE GUIDE 6 mm LOCKING NUT NYLON WASHER 2 SPECIAL BOLT 2 8 mm PIN 2 HANDLE LOCKING KNOB 2 REMOVAL INSTALLATION P 11 6 2 x 12 mm ROLL PIN 2 HANDLE ADJUSTING SPRING 2 HANDLE HEIGHT ADJUSTMENT COLLAR 2 HANDLE STAY 2 INSTALLATION P 12 5 ...

Page 137: ...t through until you can see the hole in the pin on the other side 4 Install the handle locking knob onto the top of the pin and line up the holes on the pin and the knob 5 Insert the 1 16 drift punch from the bottom to keep the two holes aligned 6 From the top side start the 2 x 12 mm roll pin and gently tap it in until it is flush with the knob 2 x 12 mm ROLL PIN 1 16 DRIFT PUNCH HANDLE LOCKING K...

Page 138: ...onnect the charge port connector on the handle below the recoil starter rope grip 2 Locate the battery charger adapter harness and connect the adapter harness into the charge port connector that is closest to the battery 3 Insert the connector on the Honda battery charger into the other end of the adapter harness 4 Plug the charger into a standard 120 volt AC power outlet and let the battery charg...

Page 139: ...e fuse to see if it is blown If the fuse blows frequently inspect the starter motor Battery 1 Charge the battery for 20 24 hours only using the appropriate Honda battery charger If the Honda battery charger is not accessible use a battery charger that charges at a maximum rate of 0 3 amps 2 Disconnect the charger and let the battery rest for 4 hours Battery voltage should be greater than 12 9 V IG...

Page 140: ...12 1 12 VARIABLE MOWING SYSTEM MOWER DECK WHEELS 1 VARIABLE MOWING SYSTEM 12 2 4 FRONT WHEELS 12 8 2 REAR SCROLL 12 5 5 REAR WHEELS 12 9 3 MOWER DECK 12 6 ...

Page 141: ... bolt that mounts the lever to the arm 4 Remove the shutter lever Installation is done in the reverse order of removal SHUTTER REMOVAL INSTALLATION REMOVAL 1 Remove the two rear 5 16 24 x 2 3 8 inch engine mounting bolts and the rear shutter holder 2 Remove the four 8 x 10 mm flange bolts and the two front shutter holders LEVER FLANGE BOLT 6 x 8 mm BOLT 5 16 24 x 2 3 8 in 2 REAR SHUTTER HOLDER FLA...

Page 142: ...me 2 Install the rear base plate and push the shutter ring into place Be sure the rear base plate bushing aligns with the shuttle lever arm Install the rear shutter holder and the two rear 5 16 24 x 2 3 8 inch engine mounting bolts Tighten the engine mounting bolts to the specified torque TORQUE 19 6 23 6 N m 14 5 17 4 ft lb SHUTTER REAR BASE PLATE SHUTTER ARM SHUTTER RING SHUTTER REAR SHUTTLE HOL...

Page 143: ... disassembly Before installation always use a new nylon lock nut TORQUE 9 8 N m 7 2 ft lb LEVER ARM REMOVAL INSTALLATION REMOVAL 1 Remove the top cover fan cover and fuel tank P 7 1 2 Remove the rear scroll P 12 5 3 Remove the retaining ring and washer 4 Remove the lever arm by pulling it out from the top of the mower INSTALLATION Installation is done in the reverse order of removal FLANGE BOLT 8 ...

Page 144: ...e scroll INSTALLATION Installation is done in the reverse order of removal When installing the scroll position the rib guide located on the top of the scroll between the belt and the Roto Stop cable After installation confirm the rib guide and Roto Stop cable are not contacting the drive belt ROLL PIN 4 x 19 8 mm BOLT 8 x 28 mm SCROLL SCROLL COLLAR 2 FLANGE BOLT 6 x 32 mm FLANGE NUT 8 mm HOLDER DR...

Page 145: ...UPPER HANDLE STAY COLLAR L LOWER HANDLE STAY COLLAR 2 HANDLE STAY HOLDER 2 HEX BOLT 8 x 50 mm HEX BOLT 8 x 40 mm FLANGE BOLT 8 x 22 mm 2 FLANGE NUT 8 mm 2 SHAFT PUSH NUT DISCHARGE GUARD SHIELD SHAFT DISCHARGE GUARD RETURN SPRING R DISCHARGE GUARD RETURN SPRING L SCROLL RAMP SELF TAPPING SCREW 5 x 16 mm 3 PUSH NUT 7 94 mm 2 SHIELD REMOVAL P 12 7 ...

Page 146: ...g rear shield If the shaft is crimped at the end as shown to the right it must be cut with a small hacksaw to be removed If the shaft is not crimped at the end pry off the existing push nut and remove the shaft 2 Install the new shaft rear shield and push nut It is not necessary to crimp the end of the replacement shaft ...

Page 147: ...arm with the square locked in while tightening the 8 mm locking nut 8 mm WASHER COLLAR ADJUSTER GRIP ADJUSTER PLATE 8 mm SELF LOCKING NUT WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE WHEEL SHAFT BOLT 22 N m 16 ft lb WHEEL INSTALLATION The HZA type has a wheel with a wheel weight installed The HYA model does not have the wheel weight Do not exchange the HZA front wheel with a repl...

Page 148: ...ER ARM L Apply some grease to outside of the adjuster arm where it fits into the cutter housing WHEEL WASHER REASSEMBLY Install the washer as shown WHEEL SIDE REAR WHEEL L PINION GEAR ORDER OF ASSEMBLY THRUST WASHER 13 mm CIRCLIP 13 mm 2 PINION GEAR 13 tooth Install with the punch mark facing Left inside Right outside SPACER 3 mm THICK 2 WASHER ADJUSTER PLATE ADJUSTER GRIP BUSHING 2 Inspect for we...

Page 149: ...12 10 VARIABLE MOWING SYSTEM MOWER DECK WHEELS HRX217HYA HRX217HZA NOTES ...

Page 150: ...13 1 13 TRANSMISSION 1 REMOVAL 13 2 2 INSTALLATION 13 4 ...

Page 151: ...wo lock nuts and disconnect the cable from the handle Leave the cable connected at the transmission 7 Cut the tie straps securing the cables to the handle pipe 8 Insert a screwdriver or rod into the hole in the transmission cable bracket and pivot the transmission to remove the belt from the pulley Disconnect the drive belt tension spring from the cable bracket 9 Remove the rear wheels drive gears...

Page 152: ...le shaft until the short axle shaft is free of the mower deck and remove the transmission The clutch cable can be left connected to the transmission 13 Remove the two 22 mm circlips and plain washers from the axle shafts TRANSMISSION CLUTCH CABLE CIRCLIP 22 mm 2 PLAIN WASHER 22 mm 2 ...

Page 153: ...f the bushings where the contact the mower deck and install the rear adjuster plates and adjuster arms Install the plain washers and 22 mm circlips on the adjusters IMPORTANT Only use an extreme pressure NLGI 2 GC LB wheel bearing grease Proper application of the correct grease is critical to ensure proper operation DO NOT USE anti seize white lithium silicone WD 40 or any other spray lubricant 6 ...

Page 154: ...nterfere with the belt or scroll Tighten the scroll mounting bolts to the specified torque 12 Install the shutter P 12 1 13 Install the wheel covers 14 Apply grease to the ends of the axle and install the ratchet return springs keys spacers and drive gears Install the 13 mm circlips The pinion gears have punch marks on them Install the left gear so the punch mark faces inside and install the right...

Page 155: ...HOLDER OIL LEVEL Remove the cap and diaphragm Fill to the top of the hole in the case with Honda hydrostatic fluid HOLE DIAPHRAGM CAP 5 x 12 mm FLANGE BOLT 2 FLANGE NUT 10 mm REMOVAL INSTALLATION Hold the shaft while removing or installing the flange nut TORQUE 26 29 N m 19 22 ft lb SHAFT FLANGE NUT CONTROL ARM ROLL PIN CONTROL ARM SPRING HOOK Position here BELT DEFLECTOR ...

Page 156: ...ppings either into the grass bag or back through the blades to be cut up into small pieces and returned to the lawn BAG MODE When the Clip Director lever is placed in the BAG position the shutter allows all of the clippings to be directed through the discharge chute and into the grass bag or discharged out the rear of the mower 1 VERSAMOW SYSTEM 14 1 3 HYDROSTATIC TRANSMISSION 14 6 2 ROTO STOP MEC...

Page 157: ...ill divert some of the grass clippings through the discharge chute The rest of the clippings will recycle through the blades to be recut and returned to the lawn as valuable mulch The amount of clippings bagged or mulched will vary depending on the position of the Clip Director lever CLIP DIRECTOR LEVER SHUTTER DISCHARGE CHUTE GRASS CLIPPINGS MULCHED CLIPPINGS ...

Page 158: ... placed in the MULCH position the shutter completely closes off the discharge chute and recycles the grass clippings through the blades The blades then recut the clippings until they fall to the lawn as valuable mulch CLIP DIRECTOR LEVER SHUTTER GRASS CLIPPINGS MULCHED CLIPPINGS ...

Page 159: ...e rotates forcing the three steel balls into the deeper part of the ramps allowing the brake plate to be pushed away from the driven disc by the ball plate spring This releases the brake and allows the clutch spring to push on the driven disc engaging the driven disc with the drive disc The drive disc is keyed to the crankshaft and drive pulley Power is transmitted to the blades for rotation BRAKE...

Page 160: ...o move down and apply the brake The brake plate pushes down on the driven disc and compress the clutch spring causing the driven disc to be released from the drive disc The application of the brake and disengagement of the clutch causes the driven disc blade holder and blades to quickly stop BRAKE PLATE BALL PLATE DRIVE DISC DRIVEN DISC BALL PLATE SPRING BRAKE APPLIED CLUTCH SPRING clutch disengag...

Page 161: ...engine speed is transmitted to the pump shaft by way of the driven pulley and it turns the pump cylinder As the pump control bowl changes its angle the pistons in the pump cylinder start a reciprocating motion PISTON SPRING PUMP CYLINDER PUMP CONTROL BOWL CASE PUMP SHAFT PUMP SHAFT PISTON PUMP CYLINDER PUMP SHAFT INLET STROKE Pistons rise To motor cylinder PISTON AT TDC Top Dead Center PISTON AT T...

Page 162: ...ns When the oil enters the inlet side of the motor cylinder the pistons are pushed out by oil pressure against the inclined plate surface causing the motor cylinder to rotate The motor speed changes according to the oil volume flow rate from the pump INLET PORT DISCHARGE PORT PLATE MOTOR CYLINDER PUMP CYLINDER AXLE SHAFT PUMP CONTROL BOWL Oil flow Rotation direction CASE PLATE MOTOR CYLINDER To pu...

Page 163: ...flows through oil passage 1 to the motor cylinder pistons The oil pressure forces the pistons out against the inclined surface causing the motor to rotate After the pistons reach top dead center they begin to compress causing oil to exit the motor cylinder and flow back to the inside of the transmission case through oil passage 2 PUMP CONTROL BOWL PUMP CYLINDER PUMP SHAFT CONTROL ARM AXLE SHAFT MO...

Page 164: ...MOTOR CYLINDER PUMP SHAFT Neutral When the clutch lever is released the pump control bowl pushes the neutral valve open and the oil flows in the reverse direction through oil passage 3 No oil flows to the motor so the lawn mower does not move PUMP CYLINDER PUMP SHAFT CONTROL ARM NEUTRAL VALVE INSIDE OF CASE OIL PASSAGE 1 MOTOR CYLINDER OIL PASSAGE 3 AXLE SHAFT PUMP CONTROL BOWL ...

Page 165: ... the pump control bowl pushes the neutral valve open When the mower is pulled backwards oil is pumped out of the motor cylinder through oil passage 1 The mower is free to roll backwards because the oil is allowed to return to the transmission case through the open neutral valve New oil is drawn into the motor cylinder through oil passage 2 PUMP CYLINDER PUMP SHAFT CONTROL ARM NEUTRAL VALVE INSIDE ...

Page 166: ...he cap is properly sealed and prevent the cap from being overtightened PRINCIPLE CHARGING Gasoline vapor produced in the fuel tank at high ambient temperature is absorbed and stored by the charcoal in the canister which is built into the fuel tank cap PURGING When the pressure in the fuel tank decreases because of low ambient temperature or consumption of gasoline the air drawn through the caniste...

Page 167: ...14 12 OPERATION HRX217HYA HRX217HZA NOTES ...

Page 168: ...13 4 Operation 14 6 I Ignition Coil Air Gap Adjustment 9 5 Disassembly Reassembly 9 7 9 10 Inspection 9 4 M Main harness routing HZA type 2 27 Maintenance Schedule 3 2 Mower Deck 12 6 Muffler 6 2 O Oil filler cap extension removal installation 10 13 Oil pan Crankshaft Piston removal installation 10 7 P Piston Connecting Rod disassembly assembly 10 10 R Rear Scroll Installation 12 5 Removal 12 5 Re...

Page 169: ...HRX217HYA HRX217HZA V Valve Clearance Adjustment 3 12 Valve Clearance Check Adjustment 3 12 Versamow System 14 1 ...

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